Multi-stage central mix and make up system for supplying any plurality of metal working machine coolant filtration systems

ABSTRACT

A system for producing and supplying a coolant to a filtration sub-system, and for reconditioning and recombining a return flow of used coolant. A main reservoir is in two way communication with the filtration sub-system via a clean coolant outlet and a dirty coolant return. An inlet feeds an untreated water supply to a de-ionization canister. A mixing valve in communication with the inlet recombines a remaining untreated portion of the water supply with the de-ionized portion. A mixing pump intermixes the water supply with a chemical concentrate to produce a coolant delivered to a main reservoir. A volume of coolant is drawn through an outlet from the reservoir and communicates the coolant to a particle filter, a chiller, and prior to outputting to the filtration sub-systems. The used return coolant is filtered and reintroduced to the main reservoir.

FIELD OF THE INVENTION

The present invention discloses a central mix and makeup system forsupplying a water/oil coolant mixture to a plurality of individual metalworking machine coolant filtration systems, the system includingreconditioning and replenishing features for treating a return/usedcoolant flow from the individual filtration systems for recirculation ina continuous and substantially closed loop cycle.

BACKGROUND OF THE INVENTION

Coolant filtration systems, such as associated with metal workingmachines, are well known in the art and which operate under theprinciple of successively filtering particles, shavings and other debrisfrom a fluid coolant, such as further mainly consisting of some level ofa treated water medium within which is dissolved a minor percentage of anatural or synthetic oil. Given the nature of the associated metalworking machines, such as which can include conveyed removal of coolantimmersed parts, it is found that significant percentages of the watercontent of the coolant (such as up to 50% within a 20-24 hour period)are evaporated.

Absent proper tracking and control, an overly oil rich coolant mixture(such as resulting from iterative addition of volumes of replenishmentcoolant exhibiting the initially fixed percentage of water to oil andwhich can exceed an arbitrarily desired range of 6-10% or higher oilemulsified within a water base) can result in significant greaterexpense and associated waste, and along with deleterious effect tocoolant performance. Degradation of performance can further result fromreverse emulsion of coolant into the water base (e.g. reduction or lossof immiscibility of the oil within the water with concurrent loss ofeffective surface area of contact within a machine cutting zone). It isfurther found that excessive oil to water percentage in the coolantfurther degrades associated coefficient of drag within the cutting zone.

Additional references are known which associate a central coolantreservoir with one or more machine located coolant filtration systems,these including such as the metalworking fluid central system ofJohnson, U.S. Pat. No. 5,224,051, the central coolant system of Harms,U.S. Pat. No. 4,655,940, the coolant re-circulating arrangement andmethod of Bratten, U.S. Pat. No. 7,338,606 and the machine tool coolantfiltration system of McEwan, U.S. Pat. No. 5,582,740.

SUMMARY OF THE INVENTION

The present invention discloses an improved system, method andassociated computer writeable medium for integrating a central mix andmakeup (CMM) tank into a fluid coolant recirculation networkcommunicating with any number or configuration of individualmetalworking machine located coolant filtration systems, this forpre-treating and conditioning an initial volume of an inlet watersupply, in combination with a calibrated type and sub-volume of oilbeing inter-mixed with the water for delivery as a coolant to any numberof the individual machine filtration systems. The CMM system and methodadditionally provides for return coolant reconditioning (such as toremove residual tramp oil and various micron sized solids andparticulates not separated by the filtration system), as well as foradjusting the relative percentages of oil to water in the replenishmentvolumes of coolant (typically reducing the oil component in aprogressive fashion) prior to adding into a main holding reservoirassociated with the CMM tank and the returned volumes of pre-circulatedcoolant, this again accounting for a rate of evaporation of water notlimited to time based upon a variety of ambient conditions and machinesetups and in order to avoid degradation of the coolant into an overlyoil rich mixture.

Most broadly, the present invention discloses a system for producing andsupplying a coolant to at least one filtration sub-system, as well asreconditioning and recombining a return flow of used coolant. A bodyincorporates a main reservoir in two way communication with thefiltration sub-system via an outlet clean coolant carrying conduit and adirty return coolant carrying conduit.

An inlet conduit includes a branching location for feeding a portion ofan untreated water supply to such as a de-ionization canister, as wellas a reverse osmosis system or other supply of low TDS (total dissolvedsolids) water with a mixing valve in communication with the inletconduit recombining a remaining untreated portion of the water supplywith the de-ionized portion, such as according to at least one variableprogrammed into a processor associated with the system such as aconductivity probe that sends an electronic signal to the PLC processorwhich adjusts the mixing valve to raise or lower the TDS level so thatthe actual reading as indicated by this probe matches the set point asdefined by the operator in the PLC processor. A mixing pump is influidic communication with an outlet of the mixing valve and intermixesthe recombined water supply with a chemical concentrate, an output ofwhich chemically represents the coolant.

A reservoir associated with the body receives a volume of coolant to afill level established by high and low parameters. A pump draws a volumeof coolant through an outlet extending from the reservoir andcommunicates the coolant to a particle filter.

A chiller located downstream from the particular filter adjusts atemperature of the coolant, an outlet of the chiller communicating withthe outlet clean coolant carrying conduit. After machine locatedfiltration, the dirty coolant is carried by the return conduit anddelivered to a re-introduction location within the main body and whichincludes a waste oil skimmer and a coalescent filter for removingresidual oil. A fluid column within the body communicates the coalescentfilter with a reintroduction location of the main reservoir forresupplying reconditioned coolant for recirculation to the filtrationsubsystems.

Additional features associated with the system include the provision ofan ozone generator and controller or air pump and diffuser forintroducing a plurality of ozone or oxygen particles within a submergedlocation of the main reservoir. A first branch line extends from anoutlet of the particle filter prior to the chiller and returns a subsetvolume of clean coolant to the main reservoir via a series of nozzlesarranged proximate a submerged floor of said reservoir. In operation,this serves to introduce a laminar agitated flow of clean coolant forpreventing residual solids within the reservoir from settling and tomaintain a constant thermal gradient and homogeneous coolantconcentration along the substantial depth of the reservoir.

A second overflow line extends from an outlet location of the chillerfor redirect back to the main reservoir a determined volume of cleancoolant outflow determined to exceed a downstream demand represented bya total number of filtration subsystems in operation. A dirty fluidoutlet from the particle filter communicates to a drain, in which islocated a sump which can further be actuated in order to push a volumeof dirty fluid through a filter and into the main body re-introductionlocation associated with the main reservoir for recirculation of thereturn coolant through the coalescent filter.

The associated processor control controls at least one additionaloperational parameter associated with the system including any one ormore of the coolant concentrate mixing pump, inlet feed valve, ozonegenerator, main pump, chiller, first branch line and second overflowline. A transducer is incorporated into the man tank such as incommunication with the sight gauge and converts pressure readings, suchas measured by determinable ranges such as 4-20 mA (milli Amps) or 0-10VDC (volts DC) as a convertible signal for determining a liquid level inthe main reservoir. Additional mechanical valves are provided as abackup and include a pair of high and low float mechanical switchesmounted within the main reservoir establishing emergency high and lowparameters, and for activating and deactivating the inlet feed valve onan emergency basis. A manual bypass valve is further provided inparallel with the inlet feed valve and which can be accessed during offline servicing, manual fill/makeup of water, or testing of the system.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference will now be made to the attached drawings, when read incombination with the following detailed description, wherein likereference numerals refer to like parts throughout the several views, andin which:

FIG. 1A is a schematic of the central mix and makeup (CMM) systemdepicting the central coolant reservoir combined with the aspects ofinitial water de-ionization and oil addition, combined with succeedingpre treatment steps associated with introduction into the reservoiralong with post machine return flow/reconditioning for dischargingwaste/solids and for continually updating a desired water/oil recipe forsubstantially closed loop recirculation;

FIG. 1B is a schematic of a selected machine located coolant filtrationsystem in operative fluid communication with the CMM system depicted inFIG. 1A;

FIGS. 1C-1E are first, second and third rotated views of the main CMMbody depicted in schematic in FIG. 1A and illustrating variouscomponents described;

FIG. 2 is a first screen illustration of an associated process controlprogram for operating the CMM system;

FIG. 3 is a succeeding main jump off screen illustration for providingaccess to all remaining screens;

FIG. 4 is a pump section screen for controlling on/off function of amain fluid pump located at an outlet of the CMM reservoir;

FIG. 5 is a system information screen for taking readings fromelectrical temperature and pressure switches in operable communicationwith a site gauge associated with the CMM fluid reservoir and whichadditionally displays filter status and controls chiller settings alongwith coolant running pressure (at calibrated depth and for determiningan actual height of the coolant water table within the reservoir) andtemperature;

FIG. 6 is a mixing tank status and adjustment screen for determining aproper fill level of the CMM reservoir;

FIG. 7 is a mixing valve screen for controlling the operation of thethree way feed water controller valve in which first and second inletsrecombine a volume of an untreated inlet water with a determined subsetvolume of pre de-ionized water, this admixture outputted for subsequentadmixture with an oil;

FIG. 8 is an optional manual adjustment screen, such as which can beaccessed from the system information screen of FIG. 5, and in which anoperator can modify various set points outside of the factorypre-settings;

FIG. 9 is a maintenance/manual override screen for optionally turningoff and on the mixing pump for filling the CMM reservoir, as well asallowing the operator to enter adjustments to PID set points associatedwith the adjustment screen of FIG. 8;

FIG. 10 is an hour meter screen for displaying a total number of hours amachine has run as well as maintaining a record filter changes includingidentification of a FIFO (first in/first out) stack identifying aprevious last twelve changes;

FIG. 11 is a deionization (DI) bottle screen for displaying a status ofthe DI bottles as well as instructing an operator when it is time toswap or replace the bottles; and

FIG. 12 is a succeeding bottle change screen for allowing the operatorto keep track of how many total gallons of water have been processedthrough the system and which also displays a number of gallons that havebeen run through a bank of bottles prior to changing such as a twelvebottle stack.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention discloses a central mix and makeup system forsupplying a water/oil coolant mixture to a plurality of individual metalworking machine coolant filtration systems, the system includingreconditioning and replenishing features for treating a return/usedcoolant flow from the individual filtration systems, combined with theability to continuously recalibrate a recipe mixture of replenishmentvolumes of coolant, for recirculation in a continuous and substantiallyclosed loop cycle.

Prior to embarking on a detailed description of the system, method andcomputer writeable medium, a brief explanation of the factors associatedwith establishing an optimal coolant according to one non-limitingexample include the desire to establish specific parameters forsustaining long term coolant effectiveness. These include each of 1)limiting the incidence of suspended solids to less than 50 ppm (partsper million) at 40 micron size or larger, 2) limiting the incidence oftramp oil in the coolant to less than 20 ppm, 3) reducing bacterial(oxygenated) content within the coolant to under 10,000 cycles, and 4)reducing dissolved solids to under 200 ppm total (90-180 beingobjectively considered to be an optimal range but not limiting in anyinstance).

Ideally, steps 1) and 4) are accomplished at the individual filtrationsystem, generally depicted at 2 in FIG. 1B, and which depicts onenon-limiting example of a suitable multi-stage filtration protocol forsuccessively removing smaller and smaller ranges of micron sizedparticulates. The filtration system 2 is intended to denote a generalrepresentation of any suitable type such as is associated with ametalworking/work-piece shaping equipment for the purpose of assistingin the removal of workpiece shavings, debris and the like.

The CMM system, process or computer writeable/assisted medium of thepresent invention generally depicted at 10 in FIG. 1A furthercontemplates being communicated, via fluid outlet 4 and return 6 linesto any plurality of individual machine located filtration systems (inthe example of FIG. 1B the selected filtration system 2 including aninlet feed line 7 communication with the CMM outlet line 4 and acorresponding outlet line 8 communicating with the CMM return line 6.Without further elaboration, it is generally noted that the filtrationsystem of FIG. 1B denotes a multi (5) stage particulate filtrationprotocol and which is referenced as being representative of anypotential type of filtration system, assembly or protocol with which theCMM system, process and process driven computer writable/assisted mediummay be integrated, again for the purpose of assisting in maintaininglong term sustained coolant integrity, combined with ensuring that adesired oil/water coolant mixture is maintained by adjusting the mixtureof replenishment volumes of coolant in response to water evaporation atthe individual filtration systems.

Referencing again the overall schematic of FIG. 1A, an untreated(typically city water) inlet fluid line is referenced at 12 and whichadmits a usually freshwater (typically well or city water) supplyexhibiting any collection of entrained solids or other particulates, phlevels, bacteria, ionization or the like. The fluid line 12 communicatesthrough an in-line sediment filter 14 which captures any larger sizedclumps of particulate (such as without limitation being 30 micron sizedor above).

Downstream from the in-line filter 4, the fluid line 12 branches into afirst line 16 successively feeding to a pair of de-ionization canisters18 and 20, as well as alternately reverse osmosis or other supply sourcefor low TDS quality water. Said canisters 18 and 20 are in combinationwith a separate branching line 22, which in turn communicates to firstand second inlets of an auto three way valve 24. The first branchingline 16 can include a series of flow regulating components including acheck valve 26, other gate/ball/globe or other valve 28, and/or a typeof flow modifying orifice 30, such as is shown prior to entering the oneor more de-ionization canisters 18 and 20. The canisters operate underthe principal of chemical exchange within a mixed bed of positively andnegatively charged (cation/anion) resins and are instructed by aprocessor control associated with the auto three way valve 24, followingan analysis of the quality and content of the inlet water 12 in order todetermine the relevant percentages of untreated and deionized water tocombine for communication through the valve 24 common output.

Following the last de-ionization canister, the branching line 16 canincorporate a further flow modifying orifice 32, a subsequentconductivity light 34 (this being a visual warning to change out thede-ionization canisters) and a further inline valve 36, following whichthe branching line 16 enters the first designated inlet of valve 24combined with a subset volume of otherwise untreated (post inline filter14) city or well water being admitted through a separate inlet. The autothree way (or proportional) valve 24 is also termed a feed watercontroller and, with reference to the succeeding control screens ofFIGS. 6 and 7, is operable for adjusting the relative percentages ofuntreated inlet feed water sub-volume with de-ionized water sub-volume,this in order to adjust (typically reduce) an amount of dissolved solidscontained within the water supply within a desired ppm (parts permillion) range by volume and conductivity. One non-limiting example of adesired outlet (makeup) feed water supply from the valve 24 can includea 4-20 mA rating with a range of 90-180 ppm dissolved solids, theparticular desired parameters of the pre-conditioned water supply(including both initial reservoir and makeup volumes) being adjustablebased upon both the nature of the raw inlet feed water and the type ofmachine filtration processing with which the eventual coolant recipe isto be supplied.

Following being outputted from the proportional valve 24, the combinedfluid is passed through an inline static mixer 38 integrated into anassociated outlet line 40 and, following that, passing through anin-line mounted probe 42 which samples the fluid mixture in order toconfirm a desired range of dissolved solids and, when necessary,instructs the controller as to adjustments to the motorized componentswithin the auto three way valve 24 in order to guarantee an acceptablemixture. A pressure gauge 43 and associated valving is provided in aline extending from a downstream location of the line 40 from the probe42 and for confirming a desired feed pressure.

A coolant concentrate mixing pump 44 is located downstream of the probe42 and draws in and introduces a suitable chemical concentrate from adrum or other volume holding container 46, via an interconnected feedline 48 into a collective outlet 49. The chemical concentrate typicallyincludes any type of natural and/or synthetic oil which is admixed withthe pre-treated water and so that a desired coolant concentration isachieved. As described previously, and depending upon the nature andapplication of the downstream located filtration systems, such a recipemixture can include an oil admixture of 0-12% per volume in comparisonto the water base within which it is admixed, with the furtherunderstanding that the replenishment volumes of water passing throughthe mixing pump 44 may exhibit reduced oil components to compensate forwater evaporation occurring at the filtration systems, and again inorder to avoid an overly rich sump or oil concentration within thecoolant over time.

A further in-line static mixer 50 is located beyond an outlet of thecoolant concentrate mixing pump 44 along merged line 49 and foroptimizing intermixing of the oil and water components and, followingthat, both an auto feed valve 52 and optional manual bypass valve 54 areprovided in parallel for introducing the mixed coolant into a main fluidholding reservoir 56 associated with a three dimensional body 58. Tankvalve readings are provided by a pressure transducer (such as forming aportion of the sight gauge assembly identified below at 64 and whichoperates by reading a fluid level 65 of the sight gauge corresponding toan overall height of the main reservoir 56. The pressure reading takenis then converted to an output reading in a defined range, such asincluding but not limited to 4-20 mA or 0-10 VDC signal, thiscorresponding to a determined tank fluid level and, depending upon theparameters programmed into the system, results in the selectiveactivation or deactivation of the associated feed valve. Backup Pressureand temperature switches are referenced at 60 and 62, respectively, incommunication with the fluid column site gauge containing a sub-volumeof coolant consistent with a fluid level 64 of the main reservoir 56,with the switches operable to determine emergency high/low fluidconditions. Either the pressure transducer or the mechanical floats workwith an associated controller program (the functionality and subroutinesof which will be subsequently described in further detail) for samplingboth temperature and pressure readings within the main tank (the lattercalculating fluid level 64 by comparing the fluid pressure at thesampled depth with a processor accessible lookup table which may againbe calibrated to any determined range of mA or VDC, and in order toreadily determine the actual fluid level within the main reservoir 56and, in response to that, to actuate the auto feed valve 52 in order torefill the reservoir to a desired level). Without further elaboration,the bypass valve 54 allows for operator intervention to manually fillthe reservoir or, more typically, to allow for fluid flow duringmaintenance/testing or the like.

Additional treatment of the CMM main reservoir 56 includes theintroduction of ozone or air from a generator/controller 66 via a feedline 68 extending to a generally floor located introduction point 70 atwhich the introduced ozone (via well known laws of molecular science)reduces the bacterial activity within the water to within the desiredrange. Also shown are high 72 and low 74 float switches within thereservoir 56 and which can cooperate with the processor driven protocolfor activating the emergency high flow level indicators.

An outlet line 76 is shown extending from the reservoir body 58 andrepresents an out-feed of coolant for subsequent delivery to the variousremote filtration systems 2. A valve 78 is disposed within the line 76and which successively extends to a main operating pump 80 (see alsoassociated processor schematic of FIG. 4 as will be subsequentlydescribed) to which is communicated a generally warm water supply drawnfrom the main reservoir 56.

The pump 80 is located in line 76 and pushes the coolant through anoutlet 81 to a series arranged succession of a mechanical pressure gauge82 with shutoff capability and a corresponding automatic pressure switch84, following which the fluid line communicates, at inlet end 86 with aparallel arrangement of sentinel filters 88 and 90, via inlet locations92 and 94, outlet locations 96 and 98, and combined out-feed 100.Separate valve controlled drain fluid outlets from the sentinel filters88 and 90 are indicated at 91 and 93 and which combine into line 95 forcommunicating the drain outlet to drain into sump 97.

As is further depicted, a series of valves are located at both inlet andoutlet locations and serve to allow for access to the filters,singularly or in tandem, to replace when dirty. Indication of a dirtyfilter can be readily determined by comparison of a reading of adownstream pressure gauge 102 with the pre-inlet gauge 84, the disparitybetween these correlating to a level of debris/particle entrapmentexisting within the filters 88 and 90 and, when achieving a certain setparameter which may or may not be dictated by the associated processorcontrol, instructing when the filters require replacement.

In practice, the sentinel filters 88 and 90 largely overlap thefunctionality of the machine located filtration system 2 in the removalof stray particulates, organic matter and the like. Prior to the outletside pressure switch 102, a branch line 104 extends from the outlet 100in order to return to the main CMM reservoir body 58 a subset volume ofcoolant. As further shown, this is represented by a series of nozzles106 proximate the submerged floor of the reservoir and which serve tointroduce a laminar agitated flow of clean coolant for preventingresidual solids within the reservoir from settling at the bottom, aswell as to maintain a constant thermal gradient and homogeneous coolantconcentration along the substantial depth of the reservoir (i.e. toprevent temperature stratification).

A major component of the clean coolant outputted from the sentinelfilters 88 and 90 proceeds through a temperature switch 108 and, basedon the reading of the outlet coolant temperature, selectively activatesa downstream chiller 110 in order to adjust the coolant temperature to adesired reading (such as without limitation within a general range of80° F.). Readings from a further pair of pressure 112 and temperatures114 switches incorporated within outlet line 4 previously identified andwhich extends from the chiller 110 compare with those of the inlet sidepressure and temperature switches 102 and 108, this in order to instructthe processor control to selectively activate and deactivate the chiller110. Without limitation, desired parameters associated with the chilleroutlet include such as a 3-10° F. drop in temperature with no more than10 psi pressure loss, combined with establishing an output volume to thefiltrations subsystems which equal to or greater than a collectivereturn flow.

A further overflow branching line 116 extends from a location of thechiller outlet line 4 and serves to redirect back to the CMM mainreservoir 56, a determined volume of coolant outflow which is determinedto exceed the collective determined downstream demand represented by thetotal number of filtration systems 2 in operation. A constant pressurevalve 118 is incorporated into the overflow line 116 and ensures that aproper return flow of clean coolant is resupplied to the CMM tank in theinstance of reduced demand.

Clean coolant proceeding along the outlet line 4 beyond the branchingline 116 and the outlet located pressure 112 and temperature switches114 is then communicated to the various remote filtration systems 2 suchas previously described in principle and, following the individual(typically multi-stage) filtration protocols, is returned via collectiveline 6 which includes an isolation (shutoff) valve 120 and succeedingorifice 122. The fluid return line 6 continues and terminates at areintroduction location 124 associated with a coalescing dirty tankportion of the main CMM body 58. The fluid return line 6 may furthersplit flow between the main tank 56 and the coalescing side reservoir(see coalescing filter subsequently identified at 144).

A foam sensor 126 is located at the reintroduction location 124 anddetermines a level of surface oil/foam present within the return coolantreservoir, with an excessive level being indicative of an overfilling ofa run off waste drum 128 which is fed by outlet line 130 communicatingthrough a concentrate (tramp) oil decant line shutoff 132 fed by a wasteoil skimmer 134. In such an instance, the sensor 126 instructs theclosing of the drain shutoff 132 to prevent such overfilling. Anexternal sump is also provided to transfer batch amounts of coolant(e.g. decanted from chip totes, etc.) back into the main coolantreservoir via sump line 138, filter 140 and tank reintroduction location142.

At this point, the return flow 6, alone or in combination with therecirculating flow 142 and less the waste foam/oil discharged throughthe skimmer 134 and drain 132, is subsequently immerse filtered througha coalescent filter stack 144 in order to separate any additional trampoils. The coalescent filter in one non-limiting application includes avolume of plasticized spheres or the like which, by virtue of theirphysical properties, attract the residual oil to their surfaces.

In this fashion, the fluid flow (see arrow 146) is communicated insucceeding downward and upward directions in which the flow reducesvelocity as it rounds a bottom disposed corner 148 and travels in anupward direction 150 along an isolated column location 152 of the CMMbody 58, prior to be discharged in spill-over fashion at an upper endlocation 154 into the main reservoir 56. The coolant at the mainreservoir re-introduction location 154 is substantially free of solidsand tramp oil and associated level of oxygenation. At this stage, thecontinuous cycle repeats with the main pump 80 withdrawing coolant fromthe main reservoir through outlet line 75 and with the processor controlaspects selectively activating/deactivating the valve 52 to furtherreplenish reservoir 56 (such as via the pressure level sensor transducerpreviously described) based upon the demand loads experienced andresulting again from factors such as the number of filtration systems 2on line and the associated evaporation level of the water component ofthe mixed coolant.

FIGS. 1C, 1D and 1E illustrate a succession of views based on the CMMmain body 58 described in schematic in FIG. 1A and depict a generallythree dimensional and pseudo rectangular shaped main holding reservoirand upon which a number of the components described in detail in FIG. 1Aare referenced. For purposes of ease of illustration, onlyrepresentative components are shown and it is further understood that anappropriate conduit network such as is represented by outlet 4 andreturn 6 lines are communicated to the CMM system.

With reference to succeeding screen shot illustrations FIGS. 2-8, anassociated processor control is described for operating the variousparameters of the CMM system previously described, these being accessedfrom and operable through a panel mounted processor 156 (see FIG. 1D)which is wired into various of the components of the CMM system and aswill be hereinafter described.

With reference first to FIG. 2, a first screen illustration 158 isillustrated of the associated process control program for operating theCMM system and in which, when power is first applied to the system, amain screen button 160 (typically of a capacitive touch screen varietyin the non-limiting variant depicted) located in a lower right handcorner can be accessed to advance to a succeeding screen;

FIG. 3 is a succeeding main jump off screen 162, accessed from the mainbutton 160 in FIG. 2, and which provides access to all remainingscreens. This includes a series of additional buttons including alarmreset 164, pump control 166, mixing tank 168, return to opening screen170, system information access 172 and mixing valve 174. For normaloperation, all this is needed to start the unit is to press pump control166 (see also 80 in FIG. 1A) and proceed to the next succeeding screenillustration (FIG. 4).

FIG. 4 is a pump section screen 176 for controlling on/off function (seeon button 178 and off button 180) of the main fluid pump 80 located atoutlet 76 of the CMM reservoir 58. When the on button 178 is depressed,an associated pump icon 182 will illuminate in a first color (e.g.green) and will also display a banner such as entitled “pump motorrunning”. Additional buttons are included at 186 for return to mainscreen 162 and for alarm reset 188.

FIG. 5 is a system information screen 190 for taking readings from theelectrical temperature 62 and pressure 60 switches in operablecommunication with the site gauge 64 associated with the CMM fluidreservoir 56 and which additionally displays both filter status andchiller settings (see representatively identified filter and chillerdifferential readouts 192 and 194). along with coolant running pressure(at calibrated depth and for determining an actual height of the coolantwater table within the reservoir) and temperature. Additional pre 196and post 198 chiller temperature readouts are indicated along with mainscreen return button 200 and alarm reset button 202.

Referring now to FIG. 6, a mixing tank status and adjustment screen 204is presented for determining a proper fill level of the CMM reservoir56. The screen 204 displays the current status of the mixing tank withnormal low/high set points from transducer signal, as well as providingboth emergency low 206 and high 208 notifications (these correspondingto mechanical low 74 and high 72 float switches. In this manner, anoperator can adjust a working range of the tank by setting fill startand stop points, these relative to the fixed nature of the E-Low 206 andE-high 208 mechanical float switch notification settings which cannot bechanged and which override the electronic settings if there is anyconflict with each other. Main screen return and alarm reset touchbuttons 210 and 212, respectively, are again provided. Additionalfunctionality includes determining at least one of water temperature andactual height of the coolant water table within the reservoir.

Proceeding to FIG. 7, a mixing valve screen is generally shown at 214for controlling the operation of the three way feed water controllervalve 24 in which the first and second inlets recombine a volume of anuntreated inlet city water with a determined subset volume of prede-ionized water, this admixture again outputted to common line 40 forsubsequent admixture with an oil (see adjustable coolant concentratemixing pump 44 with line 48 extending to chemical concentrate 46).Screen 214 further enables the user to change the set points for themixing valve 24 based upon a desired parts per million (ppm) settingwhich is desired for the recombined water sent to the adjustable coolantconcentrate mixing pump, the status of which can be reflected upon apump icon shown at 216 (e.g. red to green for in or out of rangestatus). Main return screen 218 and alarm reset 220 buttons are againprovided.

FIG. 8 is an optional manual adjustment screen 222, such as which can beaccessed from the system information screen of FIG. 5, and in which anoperator can modify various set points outside of the factorypre-settings, and such as concerning the status of the main CMMreservoir 56. These include PID disabled readout 224, such as when theauto fill valve 52 is not supplying coolant to the sump which protectsthe PID from spooling commands, as well as providing main screen access226 and maintenance access 228 buttons.

FIG. 9 is a maintenance/manual override screen 230 for optionallyturning off and on the mixing pump (via bypass valve 54) utilizing go232 and stop buttons 234 for filling the CMM reservoir 56, as well asallowing the operator to enter adjustments to PID set points associatedwith the adjustment screen of FIG. 8. Main screen return 236 and alarmreset 238 buttons are again provided.

FIG. 10 illustrates at 240 an hour meter screen for displaying a totalnumber of hours a machine has run as well as maintaining a record filterchanges including identification of a FIFO (first in/first out) stackidentifying a previous last twelve changes. A bank of twelve DI bottles(also termed filters) are listed along with a number of run time hoursassociated with each. Instructions included with the screen notify theoperator to depress LOAD button following filter change and in order tosave a number of hours run on the element.

FIG. 11 illustrates at 242 a deionization (DI) bottle screen fordisplaying a status of the DI bottles as well as instructing an operatorwhen it is time to swap or replace the bottles. As with FIG. 10, a bankof twelve filters are identified along with instructions regarding DIexchange for setting and decrementing down one position a stored numberassociated with a number of gallons of water processed through eachbottle within the bank.

Finally, FIG. 12 identifies at 244 a succeeding bottle change screen forallowing the operator to keep track of how many total gallons of waterhave been processed through the DI lead and lag bottles and which alsodisplays a number of gallons that have been run through a bank ofbottles prior to changing such as a twelve bottle stack.

In this manner, the continuous re-circulatory and makeup/replenishmentaspects of the system combine to ensure long term stability of thecoolant supply combined with maintaining a proper oil to water recipemixture (e.g. 6-12% oil for 94-88% water), this again in order tomaintain desired emulsification properties during coolant operation atthe individual filtration systems 2. In one further non-limitingexample, each associated sump reservoir incorporated into a givenmachine located filtration system 2 can turn over substantially itsentire volume every hour through continuously outflow to and resupplyfrom the main CMM reservoir and which is again returned as a cleancoolant with appropriate mixture of oil to treated and conditionedwater. Additionally, losses at each individual filtration systemreservoir can be reflected by movement within the main CMM reservoir(typically a couple of inches in overall column height 64).

An associated process for producing and supplying a coolant to at leastone filtration sub-system, as well as reconditioning and recombining areturn flow of used coolant, is also disclosed and, most broadly,includes the steps of receiving an inlet flow of untreated water,de-ionizing a subset volume of said water and recombining the untreatedand de-ionized portions within a three way valve and outputting there-combined water to a mixing pump and intermixing with a chemicalconcentrate to produce the coolant. Additional steps include feeding thecoolant into a main reservoir and successively drawing sub-volumes ofcoolant through an outlet to a particle filter for filtering out solids,chilling a filtered output to adjust a temperature of the coolant, andconveying an clean coolant from an outlet of the chiller to thefiltration subsystem.

Other steps include returning a dirty water stream from the filtrationsubsystem for delivery a re-introduction location within the bodyincluding waste oil skimming and a coalescent filtering for removingresidual oil as well as conveying reconditioned fluid from thecoalescent filter through a fluid column to a reintroduction location ofthe main reservoir and resupplying reconditioned coolant forrecirculation to the filtration subsystems.

Other steps include introducing ozone or air particles within asubmerged location of the main reservoir for biologically treating thecoolant and returning a subset volume of clean coolant from an outlet ofthe particle filter to a submerged floor location of the main reservoiras a laminar agitated flow of clean coolant for preventing residualsolids within the reservoir from settling and to maintain a constantthermal gradient along the substantial depth of the reservoir.

Additional steps include pumping a volume of a substantially untreatedfluid through a filter and into the re-introduction location associatedwith the main body to assist in foam removal and recirculation of returncoolant through the coalescent filter and for determining the main tankfluid level via the sight tube accessible pressure transducer aspreviously described.

The present invention also discloses a computer writeable mediumincorporating a processor control associated with a system for producingand supplying a coolant to at least one filtration subsystem as well asreconditioning and recombining a return flow of used coolant. Themedium, again most broadly recited, includes a first subroutine forde-ionizing a subset volume of an untreated inlet water and forrecombining untreated and de-ionized sub-volumes within a three wayvalve, a second subroutine for outputting the re-combined water to amixing pump and intermixing with a chemical concentrate to produce acoolant exhibiting a specific water to chemical recipe, and a thirdsubroutine for drawing a volume of coolant pre-deposited in a reservoirfor successive particle filtering of solids and chilling to adjust atemperature of the coolant prior to communicating to the filtrationsubsystems.

Additional subroutines include those for re-introducing a dirty returncoolant and for oil skimming and coalescent filtering for removingresidual oil, as well as for re-conveying reconditioned fluid from thecoalescent filter through a fluid column to a reintroduction location ofthe main reservoir and resupplying reconditioned coolant forrecirculation to the filtration subsystems.

Yet additional subroutines associated with the computer writeable mediumcan include, without limitation in reference to the cumulative precedingdisclosure, introducing ozone or air particles within a submergedlocation of the main reservoir for biologically treating the coolant andreturning subset volumes of clean coolant from an outlet of the particlefilter to a submerged floor location of the main reservoir as a laminaragitated flow of clean coolant for preventing residual solids within thereservoir from settling and to maintain a constant thermal gradientalong the substantial depth of the reservoir. Additional subroutines caninclude redirecting an overflow of clean coolant from an outlet locationof the chiller back to the main reservoir which exceeds a downstreamdemand represented by a total number of filtration subsystems inoperation.

Other additional subroutines drawn from the above disclosure includepumping a volume of a substantially untreated fluid through a filter andinto the re-introduction location associated with the main body toassist in foam removal and recirculation of return coolant through thecoalescent filter and sampling a fluid pressure from a site gaugeassociated with the main reservoir in order to trip either of high andlow float mechanical switches submerged within the main reservoir foractivating a feed valve for supplying coolant to the reservoir. Finally,other subroutines can include varying an additive component of chemicalconcentrate added to replenishment volumes of coolant in order tomaintain an overall recipe mixture of chemical to water components whenintroduced into the main reservoir, and again thereby avoid anundesirable oil-rich sump composition.

Having described our invention, other and additional preferredembodiments will become apparent to those skilled in the art to which itpertains, and without deviating from the scope of the appended claims.

I claim:
 1. A system for producing and supplying a coolant to at leastone filtration subsystem as well as reconditioning and recombining areturn flow of used coolant, said system comprising: a bodyincorporating a main reservoir in two way communication with thefiltration sub-system via an outlet clean coolant carrying conduit and adirty return coolant carrying conduit; an inlet conduit including abranching location for feeding a portion of an untreated water supply toa de-ionization canister; a mixing valve in communication with saidinlet conduit and recombining a remaining untreated sub-volume of thewater supply with the de-ionized sub-volume according to at least onevariable programmed into a processor associated with said system; amixing pump in fluidic communication with an outlet of said mixing valveand intermixing the recombined water supply with a chemical concentrate,an output of which chemically represents the coolant; a main reservoirassociated with said body and, upon actuation of an inlet feed valve incommunication with an outlet of said mixing pump, receiving a volume ofcoolant to a fill level established by high and low parameters; a mainpump drawing a volume of coolant through an outlet extending from saidreservoir and communicating said coolant to a particle filter; a chillerlocated downstream from said particular filter for adjusting atemperature of the coolant, an outlet of said chiller communicating withthe outlet clean coolant carrying conduit; the return coolant carryingconduit delivering the dirty coolant to a re-introduction location ofsaid body and which includes a waste oil skimmer and a coalescent filterfor removing residual oil from the dirty coolant; and a fluid columncommunicating said coalescent filter with a reintroduction location ofsaid main reservoir for resupplying reconditioned coolant forrecirculation to the filtration subsystems.
 2. The system as describedin claim 1, further comprising at least one of an ozone generator or airpump and controller for introducing a plurality of ozone or airparticles within a submerged location of said main reservoir.
 3. Thesystem as described in claim 1, further comprising a first branch lineextending from an outlet of said particle filter prior to said chillerand returning a subset volume of clean coolant to said main reservoirvia a series of nozzles arranged proximate a submerged floor of saidreservoir and which serves to introduce a laminar agitated flow of cleancoolant for preventing residual solids within said reservoir fromsettling and to maintain a constant thermal gradient along thesubstantial depth of said reservoir.
 4. The system as described in claim3, further comprising a second overflow line extending from an outletlocation of said chiller for redirect back to said main reservoir adetermined volume of clean coolant outflow determined to exceed adownstream demand represented by a total number of filtration subsystemsin operation.
 5. The system as described in claim 1, further comprisinga dirty fluid outlet from said particle filter communicating to a drain.6. The system as described in claim 5, further comprising a sump locatedwithin said drain and pushing a volume of dirty fluid through a filterand into said main reservoir.
 7. The system as described in claim 4,further comprising said processor controlling at least one additionaloperational parameter associated with said system including said coolantconcentrate mixing pump, inlet feed valve ozone generator, air pump,main pump, chiller, said first branch line and said second overflowline.
 8. The system as described in claim 1, further comprising apressure transducer in communication with said main reservoir forconverting an input pressure reading to an output signal calibrated todetermine the fluid level within the main reservoir.
 9. The system asdescribed in claim 8, further comprising a manual bypass valve inparallel with said inlet feed valve.
 10. The system as described inclaim 1, said particle filter further comprising a pair of sentinelfilters mounted in parallel, pressure switches being mounted with commoninlet and outlet lines associated with said filters and instructingfilter removal upon reaching a set variable.
 11. The system as describedin claim 8, further comprising pressure and temperature switches incommunication with said main reservoir and, along with said pressuretransducer, interfacing with an associated controller program in orderto for determining preset emergency high and low fluid levels.
 12. Aprocess for producing and supplying a coolant to at least one filtrationsubsystem as well as reconditioning and recombining a return flow ofused coolant, comprising the steps of: receiving an inlet flow ofuntreated water; de-ionizing a subset volume of said water andrecombining the untreated and de-ionized sub-volumes within a three wayvalve; outputting the re-combined water to a mixing pump and intermixingwith a chemical concentrate to produce the coolant; feeding the coolantinto a main reservoir associated with a body and successively drawingsub-volumes of coolant through an outlet to a particle filter forfiltering out solids; chilling a filtered output to adjust a temperatureof the coolant; conveying an clean coolant from an outlet of the chillerto the filtration subsystem; returning a dirty from the filtrationsubsystem for delivery a re-introduction location within the bodyincluding waste oil skimming and a coalescent filtering for removingresidual oil; and conveying reconditioned fluid from the coalescentfilter through a fluid column to a reintroduction location of the mainreservoir and resupplying reconditioned coolant for recirculation to thefiltration subsystems.
 13. The process as described in claim 12, furthercomprising the step of introducing ozone or air particles within asubmerged location of the main reservoir for biologically treating thecoolant.
 14. The process as described in claim 12, further comprisingthe step of returning a subset volume of clean coolant from an outlet ofthe particle filter to a submerged floor location of the main reservoiras a laminar agitated flow of clean coolant for preventing residualsolids within the reservoir from settling and to maintain a constantthermal gradient along the substantial depth of the reservoir.
 15. Theprocess as described in claim 12, further comprising the step of pumpinga volume of a substantially untreated fluid through a filter and intothe re-introduction location associated with the main body to assist infoam removal and recirculation of return coolant through the coalescentfilter.
 16. The process as described in claim 12, further comprising thestep of sampling a fluid pressure from a site gauge associated with themain reservoir using a pressure transducer and for converting thepressure reading to an output reading for determining a fluid levelwithin said main reservoir.
 17. A computer writeable mediumincorporating a processor control associated with a system for producingand supplying a coolant to at least one filtration subsystem as well asreconditioning and recombining a return flow of used coolant,comprising: a first subroutine for de-ionizing a subset volume of anuntreated inlet water and for recombining untreated and de-ionizedsub-volumes within a three way valve; a second subroutine for outputtingthe re-combined water to a mixing pump and intermixing with a chemicalconcentrate to produce a coolant exhibiting a specific water to chemicalrecipe; a third subroutine for drawing a volume of coolant pre-depositedin a reservoir for successive particle filtering of solids and chillingto adjust a temperature of the coolant prior to communicating to thefiltration subsystems; a fourth subroutine for re-introducing a dirtyreturn coolant and for oil skimming and coalescent filtering forremoving residual oil; and a fifth subroutine for re-conveyingreconditioned fluid from the coalescent filter through a fluid column toa reintroduction location of the main reservoir and resupplyingreconditioned coolant for recirculation to the filtration subsystems.18. The computer writeable medium as described in claim 17, furthercomprising an additional subroutine for introducing ozone or airparticles within a submerged location of the main reservoir forbiologically treating the coolant.
 19. The computer writeable medium asdescribed in claim 17, further comprising an additional subroutine forreturning a subset volume of clean coolant from an outlet of theparticle filter to a submerged floor location of the main reservoir as alaminar agitated flow of clean coolant for preventing residual solidswhich the reservoir from settling and to maintain a constant thermalgradient along the substantial depth of the reservoir.
 20. The computerwriteable medium as described in claim 17, further comprising anadditional subroutine for redirecting an overflow of clean coolant froman outlet location of the chiller back to the main reservoir whichexceeds a downstream demand represented by a total number of filtrationsubsystems in operation.
 21. The computer writeable medium as describedin claim 17, further comprising an additional subroutine for activatinga sump for pumping an external coolant back into the main reservoir. 22.The computer writeable medium as described in claim 17, furthercomprising an additional subroutine for sampling a fluid pressure from asite gauge associated with the main reservoir and for converting thepressure to an output signal in a determined range not limited to 4-20mA and 0-10 VDC, for determining the main reservoir.
 23. The computerwriteable medium as described in claim 17, further comprising anadditional subroutine for varying an additive component of chemicalconcentrate added to replenishment volumes of coolant in order tomaintain an overall recipe mixture of chemical to water components whenintroduced into the main reservoir.